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The Process
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 Ten thousand years ago as the ice age came to a close and
glaciers across Europe retreated north, glacial melt water
carried organic clay into deposits such as that found close
to the River Blackwater in East County Cork.
For two hundred and fifty years this clay has been used to
create the earthenware pots, plates and bowls for which
the potters of the region became renowned.
Shanagarry is at the heart of this region. From its height in
the eighteenth century when seven major potteries existed in
the nearby town of Youghal, the craft and tradition of the potter
had gone into decline until it ceased altogether in about 1940. Stephen's parents Philip and
Lucy Pearce arrived in the area in 1953 and revived the tradition of pottery making in East
Cork. They were instructed in the art of pottery by Willie Greene, one of the last surviving master
potters from Youghal. Together, Philip and Lucy founded Shanagarry Pottery.
To create a pot of function and beauty from clay taken from the Irish landscape involves eighteen
distinct hand processes.
Our traditional methods of pottery making have changed very little since the time of the old
Youghal potteries, where skilled craftsmen produced urns, jars and vases from natural clay
that had lay dormant in our countryside for thousands of years.
Our clay is carefully selected and dug from our own clay field in Youghal in Co. Cork. The clay
is brought to Shanagarry for weathering where it is exposed to the elements of sun, rain and frost
before it begins its long journey to becoming a pot.
After several months weathering, the clay is mixed with water to make a brown creamy liquid
called slip clay. This liquid clay is then put through a sieving process to remove small stones
and grit. Once the clay is pure it is pumped into the filter press, which squeezes (presses) most
of the water back out of the clay. The clay is removed from the filter press in large soft putty-like
slabs (cakes). These clay slabs are then put through the pug mill, which will expel all the air from
the clay and extrude it into rolls. The rolls of clay are stored and aged in cold damp conditions
for four months before they are ready for use by the potters.
 
After this time the clay is selected and weighed and taken to the potters wheel. The potters carefully
mould and shape the clay into the pot shape. This process is called throwing.
The pot is cut from the wheel with a wire and placed on a bat to dry.
Bowls, plates and dishes are selected before they are completely dry for the process of turning.
These pots are returned and placed upside down on the wheel where they are carefully trimmed
and shaved with a tool to complete the correct shape. This process is very similar to wood turning.
Handles are attached to cups, mugs and jugs at exactly the right time during the drying process.
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Once the pots are completely dry they are stacked in the kiln for the first firing (baking). It is in
this process of firing that the clay changes to pottery.
The pots are taken from the kiln when cooled. They are decorated and glazed in different ways,
some by dipping into a vat of glaze, some by pouring glaze into the pot and others by painting a
hot wax onto the surface of the pot. The pots are then returned to the kiln for the second firing
(glaze firing). As the heat rises in the kiln the glaze begins to melt and become molten, turning
into a white glass and sealing the surface of the pot. |
When the pots are taken from the glaze kiln, eighteen hours later, the long process is complete.
The once heavy damp brown clay which lay dormant in the Blackwater valley has come to life in
shades of rich toasty terracotta colours clothed in a warm creamy white glaze.
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